CN113551531A - Automatic control system of reaction furnace and state monitoring device of reaction furnace - Google Patents
Automatic control system of reaction furnace and state monitoring device of reaction furnace Download PDFInfo
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- CN113551531A CN113551531A CN202110837690.6A CN202110837690A CN113551531A CN 113551531 A CN113551531 A CN 113551531A CN 202110837690 A CN202110837690 A CN 202110837690A CN 113551531 A CN113551531 A CN 113551531A
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D11/00—Arrangement of elements for electric heating in or on furnaces
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangements of monitoring devices; Arrangements of safety devices
- F27D21/0014—Devices for monitoring temperature
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D9/00—Cooling of furnaces or of charges therein
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D9/00—Cooling of furnaces or of charges therein
- F27D2009/0002—Cooling of furnaces
- F27D2009/0005—Cooling of furnaces the cooling medium being a gas
Abstract
The present disclosure provides a reactor automatic control system and a reactor state monitoring device. Wherein, reaction furnace automatic control system includes: the data acquisition module is used for acquiring an environment image in the reaction furnace; the data processing module is connected with the data acquisition module and used for acquiring temperature field data and a combustion state according to the environment image and determining an operation parameter adjusting value of the reaction furnace according to the temperature field data and the combustion state; and the control module is connected with the data processing module and the reaction furnace and is used for adjusting the operation parameters of the reaction furnace according to the received operation parameter adjusting values. Through the automatic control system of the reaction furnace provided by the embodiment of the disclosure, the automatic control efficiency and the automation degree of the reaction furnace are improved.
Description
Technical Field
The disclosure relates to the technical field of automatic control, and particularly provides a reaction furnace automatic control system and a reaction furnace state monitoring device for automatically controlling the operation process of a reaction furnace.
Background
The reactor is a device which can burn solid fuel, waste gas, waste liquid, medical garbage, domestic waste, animal corpses and the like at high temperature, reduce the quantitative number or reduce the quantitative number and utilize the heat energy of part or all burning media. The operation process of the reaction furnace relates to the working procedures of feeding, screening, drying, burning, ash removal, dust removal and the like. In the related art, the technical measures of high-temperature combustion and secondary oxygen addition are generally used for providing reaction conditions for reactants in the reaction furnace, so that an operator needs to observe and record the combustion condition in the reaction furnace and adjust parameters of each process of the reaction furnace according to the combustion condition in the reaction furnace to control the reactant to be sufficiently combusted. The judgment method excessively depends on manual experience, and wastes time and labor, so that the control efficiency of the reaction furnace is low.
It is to be noted that the information disclosed in the above background section is only for enhancement of understanding of the background of the present disclosure, and thus may include information that does not constitute prior art known to those of ordinary skill in the art.
Disclosure of Invention
An object of the present disclosure is to provide a reactor automatic control system and a reactor status monitoring apparatus for overcoming, at least to some extent, the problem of inefficient reactor control due to the limitations and disadvantages of the related art.
According to an aspect of the embodiments of the present disclosure, there is provided a reaction furnace automatic control system including: the data acquisition module is used for acquiring an environment image in the reaction furnace; the data processing module is connected with the data acquisition module and used for acquiring temperature field data and a combustion state according to the environment image and determining an operation parameter adjusting value of the reaction furnace according to the temperature field data and the combustion state; and the control module is connected with the data processing module and the reaction furnace and is used for adjusting the operation parameters of the reaction furnace according to the received operation parameter adjusting values.
In an exemplary embodiment of the disclosure, the data acquisition module is further configured to acquire operating condition data of the reaction furnace, and the data processing module is further configured to determine an operating parameter adjustment value of the reaction furnace according to the operating condition data, the temperature field data, and the combustion state.
In an exemplary embodiment of the present disclosure, the data processing module includes: the combustion state identification unit is used for identifying the environment image through a preset neural network model so as to obtain a combustion state, wherein the combustion state comprises at least one of combustion abnormity of a combustion section, combustion abnormity of a burnout section, smoke abnormity, reactant thickness abnormity and furnace shutdown; the temperature field identification unit is used for identifying the environment image according to a preset temperature calibration relation to acquire temperature field data, wherein the temperature field data comprises a plurality of temperature values corresponding to the environment image, and the preset temperature calibration relation is a corresponding relation between image pixels and the temperature values; and the operating parameter determining unit is used for determining an operating parameter adjusting value of the reaction furnace according to the temperature field data and the combustion state.
In an exemplary embodiment of the present disclosure, when the combustion state is abnormal combustion in the combustion section and the first ratio of the temperature field data is less than or equal to a first preset threshold, the operation parameter determining unit determines an intake air amount increase value and a grate speed increase value, where the first ratio is a ratio of the number of temperature values exceeding the combustion temperature in the preset combustion section to the total number of the temperature values, the intake air amount increase value is used to increase the intake air amount of the reaction furnace, and the grate speed increase value is used to increase the grate speed of the reaction furnace.
In an exemplary embodiment of the present disclosure, when the combustion state is the combustion abnormality of the ember section and the second ratio of the temperature field data is greater than or equal to a second preset threshold, the operation parameter determination unit determines an intake air amount reduction value and a grate speed reduction value, the second ratio being a ratio of the number of temperature values greater than the combustion temperature of the ember section to the total number of temperature values, the intake air amount reduction value being used to reduce the intake air amount of the reaction furnace, and the grate speed reduction value being used to reduce the grate speed of the reaction furnace.
In an exemplary embodiment of the present disclosure, the operation parameter determination unit determines the intake air amount increase value when the combustion state is a smoke abnormality and the maximum temperature value in the temperature field data is less than or equal to a preset smoke temperature.
In an exemplary embodiment of the present disclosure, when the combustion state is an abnormal reactant thickness and the maximum temperature value in the temperature field data is less than or equal to a preset reactant thickness compliant combustion temperature, the operation parameter determination unit determines the intake air amount increase value and the grate speed increase value.
In an exemplary embodiment of the present disclosure, when the combustion state is furnace shutdown and a third ratio in the temperature field data is less than or equal to a third preset threshold, the operation parameter determination unit determines that the intake air amount of the reactor, the feeding amount of the reactor, and the grate speed of the reactor are zero, and the third ratio is a ratio of the number of temperature values less than the preset furnace shutdown temperature and the total number of temperature values.
In an exemplary embodiment of the present disclosure, the above automatic control system for a reaction furnace further includes: and the protection module is connected with the data acquisition module and is used for acquiring the external environmental parameters of the data acquisition module and controlling the data acquisition module to enter or exit the reaction furnace according to the environmental parameters.
According to another aspect of the embodiments of the present disclosure, there is provided a reactor state monitoring apparatus including: the data acquisition module is arranged on the side wall of the hearth of the reaction furnace and used for acquiring an environment image inside the reaction furnace; the data processing module is connected with the data acquisition module and used for determining the temperature field data and the combustion state of the reaction furnace according to the environment image; and the automatic advance and retreat protection module is arranged outside and used for acquiring the external environmental parameters of the data acquisition module and controlling the data acquisition module to enter or exit the reaction furnace according to the environmental parameters.
The automatic control system of the reaction furnace provided by the embodiment of the disclosure can automatically control the operation process of the reaction furnace without manual monitoring by acquiring the environment image in the reaction furnace and determining the combustion state and the temperature field data in the reaction furnace according to the environment image so as to determine the operation parameter adjusting value of the reaction furnace in real time and automatically adjusting the operation parameter of the reaction furnace according to the operation parameter adjusting value, so that reactants are fully combusted, and the automatic control efficiency of the reaction furnace can be effectively improved.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present disclosure and together with the description, serve to explain the principles of the disclosure. It is to be understood that the drawings in the following description are merely exemplary of the disclosure, and that other drawings may be derived from those drawings by one of ordinary skill in the art without the exercise of inventive faculty.
FIG. 1 shows a schematic diagram of an automated reactor control system in an embodiment of the disclosure;
FIG. 2 is a schematic diagram illustrating an environmental image in an embodiment of the present disclosure;
FIG. 3 shows a block diagram of a data processing module in an embodiment of the disclosure;
FIG. 4 is a schematic illustration of a display interface for combustion status in an embodiment of the present disclosure;
FIG. 5 is a schematic diagram of an automatic control system for a reactor according to an embodiment of the present disclosure;
FIG. 6 is a schematic diagram illustrating an overall work environment in an embodiment of the disclosure;
FIG. 7 is a schematic diagram illustrating another overall operating environment in an embodiment of the disclosure;
FIG. 8 is a schematic diagram illustrating the operation of a reactor according to an embodiment of the present disclosure;
fig. 9 shows a schematic diagram of a state monitoring device of a reaction furnace in an embodiment of the present disclosure.
Detailed Description
Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments may, however, be embodied in many different forms and should not be construed as limited to the examples set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of example embodiments to those skilled in the art. The described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to give a thorough understanding of embodiments of the disclosure. One skilled in the relevant art will recognize, however, that the subject matter of the present disclosure can be practiced without one or more of the specific details, or with other methods, components, devices, steps, and the like. In other instances, well-known technical solutions have not been shown or described in detail to avoid obscuring aspects of the present disclosure.
Furthermore, the terms "first", "second", etc. are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present disclosure, "a plurality" means at least two, e.g., two, three, etc., unless explicitly specifically limited otherwise. The symbol "/" generally indicates that the former and latter associated objects are in an "or" relationship.
In the present disclosure, unless otherwise expressly specified or limited, the terms "connected" and the like are to be construed broadly, e.g., as meaning electrically connected or in communication with each other; may be directly connected or indirectly connected through an intermediate. The specific meaning of the above terms in the present disclosure can be understood by those of ordinary skill in the art as appropriate.
Further, the drawings are merely schematic illustrations of the present disclosure, in which the same reference numerals denote the same or similar parts, and thus, a repetitive description thereof will be omitted. Some of the block diagrams shown in the figures are functional entities and do not necessarily correspond to physically or logically separate entities. These functional entities may be implemented in the form of software, or in one or more hardware modules or integrated circuits, or in different networks and/or processor devices and/or microcontroller devices.
The automatic control system of the reactor according to the exemplary embodiment will be described in more detail with reference to the drawings and examples.
FIG. 1 is a schematic diagram of a reactor furnace automatic control system in an exemplary embodiment of the present disclosure.
Referring to fig. 1, the automatic reaction furnace control system 100 includes: a data acquisition module 102, a data processing module 104, and a control module 106. The data acquisition module 102 is connected to the data processing module 104, and the data processing module 104 is connected to the control module 106. The data acquisition module 102 sends the acquired environmental image in the reaction furnace to the data processing module 104, the data processing module 104 identifies the environmental image to acquire temperature field data and combustion state in the reaction furnace and determine an operation parameter adjustment value of the reaction furnace, and the control module 106 receives the operation parameter adjustment value sent by the data processing module 104 and adjusts the operation parameter of the reaction furnace.
In one embodiment, the data acquisition module 102 may be, for example, an industrial camera. The industrial camera device can be arranged on the side wall of the hearth close to the combustion section area in the reaction furnace or on the side wall of the hearth close to the burnout section area in the reaction furnace. The environment images shot at different installation positions are different.
FIG. 2 is a schematic diagram of an environmental image in one embodiment of the present disclosure.
As shown in FIG. 2, the environmental image 200 may include a burn-out stage area 202 and a burn-out stage area 204 when the industrial camera is positioned on a sidewall of the furnace within the reactor proximate the burn-out stage area. The combustion zone 204 corresponds to a combustion zone within the reaction furnace, and the ember zone 204 corresponds to an ember zone of the reaction furnace.
The area covered by the flame generated when the reactant is combusted in the combustion section is the combustion section flame area, the product generated after the reactant is combusted is the reaction product, and the area covered by the flame generated when the reactant or the reaction product is combusted in the ember section is the ember section flame area.
FIG. 3 is a block diagram of a data processing module in one embodiment of the disclosure. The data processing module shown in fig. 3 may be used to implement the functionality of the data processing module 104 of fig. 1 described above.
As shown in fig. 3, the data processing module 300 may include a combustion state identification unit 302, a temperature field identification unit 304, and an operating parameter determination unit 306. The combustion state identification unit 302 is configured to identify an environment image through a preset neural network model to obtain a combustion state, where the combustion state includes at least one of combustion anomaly in a combustion section, combustion anomaly in an ember section, smoke anomaly, reactant thickness anomaly, and furnace shutdown. The temperature field identification unit 304 is configured to identify the environmental image according to a preset temperature calibration relationship to obtain temperature field data. The operation parameter determining unit 306 respectively obtains the combustion state identified by the combustion state identifying unit 302 and the temperature field data identified by the temperature field identifying unit 304, and determines the operation parameter adjustment value of the reaction furnace according to the temperature distribution rule reflected by the temperature field data and the reaction state of the reaction furnace reflected by the combustion state.
In one embodiment, the temperature field data may include a plurality of temperature values corresponding to the environmental image. The temperature field identification unit 304 may determine, according to a preset temperature calibration relationship, each temperature value corresponding to image feature data of different pixel points in the environment image, where the image feature data may be, but is not limited to, brightness, gray scale, and contrast of an image pixel. In the embodiment of the present disclosure, the preset temperature calibration relationship may be obtained by using a black body furnace calibration method. The blackbody furnace is an ideal object which can completely absorb external radiation energy and can completely radiate the whole energy of the blackbody furnace, and the temperature of the blackbody furnace can be set in advance. The black body furnace calibration method comprises the following steps: the method comprises the steps of measuring the surface temperature of the black body furnace, photographing the black body furnace by using an industrial camera device to generate a thermal image, simultaneously acquiring image characteristic data in the thermal image, obtaining a fitting curve between the surface temperature of the black body furnace and the image characteristic data in the thermal image by using a least square method, and then correcting the fitting curve according to the current set temperature of the black body furnace. Therefore, the corrected fitting curve can reflect the mapping relation between the image characteristic data of the image pixels and the temperature values, and the mapping relation is the preset temperature calibration relation.
In one embodiment, the environment image may include a combustion section area and an ember section area of the flame, the temperature field data obtained by identifying the environment image may include a temperature value of the combustion section area and a temperature value of the ember section area, and the temperature distribution rules of the combustion section area and the ember section area may be obtained according to the temperature value of the combustion section area and the temperature value of the ember section area, respectively. Wherein, the burning section area is an area for stacking and effectively burning reactants in the reactor, the products after the reactants are burned are reaction products, and the burnout section area is an area for stacking and effectively burning the reaction products in the reactor.
The operation parameter determining unit 306 obtains the temperature values of the combustion section area 202 and the temperature values of the ember section area 204 in the environment image through the temperature field identifying unit 304, determines that the ratio of the number of the temperature values larger than the preset combustion temperature in the combustion section area 202 to the total number of the temperature values of the combustion section area 202 is a first ratio, determines that the ratio of the number of the temperature values larger than the preset combustion temperature in the ember section area 204 to the total number of the temperature values of the ember section area 204 is a second ratio, and determines that the ratio of the number of the temperature values smaller than the preset furnace shutdown temperature in the environment image to the total number of the temperature values of the environment image is a third ratio.
The preset combustion temperature of the combustion section, the preset combustion temperature of the burnout section and the preset blow-out temperature may be preset temperatures. The preset soot temperature may be an average of historical soot temperatures within the reaction furnace. The preset combustion temperature for the thickness of the reactant reaching the standard can be the combustion temperature when the thickness of the reactant in the reaction furnace reaches a preset standard value.
In the embodiment of the present disclosure, the combustion state identification unit 302 may directly identify the environment image through the preset neural network model to obtain the combustion state, and the combustion state may reflect the combustion state of the reaction product in the reaction furnace. For example, when the combustion state acquired by identifying the environment image is combustion abnormality of a combustion section or combustion abnormality of an ember section, the reactant can be determined to be in an abnormal combustion state; for another example, if the combustion state acquired from the environment image is recognized as a furnace shutdown, the reactant can be determined as a combustion-stopped state, i.e., a furnace shutdown state.
The type of the preset neural network model may be, for example, a convolutional neural network model, before the environment image is input into the preset neural network model, image denoising processing may be performed on the environment image, and the processing method may include, for example, denoising, filtering processing, normalization, grayscaling, and the like, which is not limited in this disclosure.
The pre-set neural network model may be pre-trained by the artificial labeling data. In one embodiment, the operator may use the image marking tool to mark the flame coverage of the combustion zone and the ember zone, the extent of the combustion zone and the ember zone, and the reactant accumulation extent of the combustion zone and the ember zone on the environmental image.
Generating a training sample according to the marked environment image, training a preset neural network model by using the training sample, wherein the trained preset neural network model can identify the flame coverage range of a combustion section area and an ember section area, the range of the combustion section area and the ember section area, and the reactant accumulation range of the combustion section area and the ember section area in the environment image, and further calculate the areas of the combustion section area and the ember section area and the area of the flame coverage range of the combustion section area and the ember section area according to the identification result.
In the embodiment of the present disclosure, a ratio of an area of a flame coverage area of the combustion section region to an area of the combustion section region is taken as a first ratio, a ratio of a reactant stacking height of the combustion section region to a height of the combustion section region is taken as a second ratio, a ratio of an area of a flame coverage area of the ember section region to an area of the ember section region is taken as a third ratio, and a ratio of a reactant stacking height of the ember section region to a height of the ember section region is taken as a fourth ratio.
The preset neural network model can be set as follows: when the first proportion is smaller than a first preset proportion, the output data of the neural network model is preset as abnormal combustion of the combustion section; when the third proportion is larger than the second preset proportion, the output data of the neural network model is preset to be abnormal combustion of the burn-out section; when the third proportion is smaller than the second preset proportion, the output data of the neural network model is preset to be normal combustion; when the sum of the first proportion and the third proportion is smaller than a third preset proportion, the output data of the neural network model is preset to be abnormal smoke; when the first proportion plus the third proportion is smaller than the fourth preset proportion, the output data of the neural network model is preset to be in a blowing-out state; when the second proportion is larger than a fifth preset proportion or the fourth proportion is larger than a sixth preset proportion, presetting the output data of the neural network model as reactant thickness abnormity;
the first predetermined ratio may be, for example, 5%, the second predetermined ratio may be, for example, 95%, the third predetermined ratio may be, for example, 3%, the fourth predetermined ratio may be, for example, 1%, the fifth predetermined ratio may be, for example, 1/3, and the sixth predetermined ratio may be, for example, 1/2, but is not limited thereto.
FIG. 4 provides a display interface that displays the combustion status of the environmental image to an operator.
As shown in fig. 4, the display interface 400 includes a parameter setting area 402, an image display area 404, a combustion state display area 406, a log information display area 408, an image histogram 410, and an image temperature display area 412. The parameter setting area 402 is used for providing an interface for manually setting the parameters of the reaction furnace, and the image display area 404, the log information display area 408, the image histogram 410 and the image temperature display area 412 are used for displaying the identification result of the environment image.
The image display area 404 is used for displaying the collected environment image and the generated temperature field pseudo color image, the log information display area 408 is used for outputting log information of the operation of the reaction furnace, the image histogram 410 is used for displaying the distribution condition of pixel values in the environment image, and the image temperature display area 412 is used for displaying the temperature curve of the image temperature measurement, including the maximum temperature, the minimum temperature and the average temperature. The temperature field pseudo color image is generated according to temperature field data of the environment image, and different colors in the temperature field pseudo color image represent different temperature values.
The combustion status display area 406 is used to display the combustion status corresponding to the environmental image, and may use indicator lights with different colors to indicate the combustion status, for example, when the combustion status is normal combustion, the label is green, and when the combustion status is abnormal reactant thickness, the label is red.
In this disclosure, the operation parameter determining unit 306 may obtain a first preset threshold, a second preset threshold, and a third preset threshold that are preset, and when the combustion state of the environment image is normal combustion, if it is determined that the first ratio is greater than the first preset threshold and the second ratio is smaller than the second preset threshold, it is determined that the temperature field data of the environment image is consistent with the combustion state, and the reaction furnace is in the normal combustion state, and it is not necessary to determine the operation parameter adjustment value of the reaction furnace.
When the combustion state of the environment image is abnormal combustion of the combustion section, if the first ratio is judged to be smaller than or equal to the first preset threshold value, the temperature field data of the environment image is consistent with the combustion state, and the air intake increasing value and the grate speed increasing value are determined when the combustion state of the reaction furnace is abnormal combustion of the combustion section.
When the combustion state of the environment image is abnormal combustion of the burnout section, if the second ratio is judged to be larger than or equal to the second preset threshold value, the temperature field data of the environment image is consistent with the combustion state, and the combustion state of the reaction furnace is abnormal combustion of the burnout section, and the intake air reduction value and the grate speed reduction value are determined.
When the combustion state of the environment image is abnormal smoke, if the maximum temperature value of the environment image is judged to be less than or equal to the preset smoke temperature, the temperature field data of the environment image is determined to be consistent with the combustion state, the combustion state of the reaction furnace is abnormal smoke, and the air intake increase value is determined.
When the combustion state of the environment image is that the thickness of the reactant is abnormal, if the minimum temperature value of the environment image is judged to be less than or equal to the preset reactant thickness standard combustion temperature, the temperature field data of the environment image is determined to be consistent with the combustion state, the combustion state of the reaction furnace is that the thickness of the reactant is abnormal, and the intake air amount increase value and the grate speed increase value are determined.
And when the combustion state of the environment image is blowing out, if the third ratio is judged to be less than or equal to a third preset threshold value, determining that the temperature field data of the environment image is consistent with the combustion state, blowing out the reaction furnace, and determining that the air intake of the reaction furnace, the feeding amount of the reaction furnace and the grate speed of the reaction furnace are zero.
In the above embodiment, if it is determined that any one of the first ratio is greater than the first preset threshold or the second ratio is smaller than the second preset threshold is not true, or it is determined that the first ratio is greater than the first preset threshold, or it is determined that the second ratio is smaller than the second preset threshold, or it is determined that the maximum temperature value of the environmental image is greater than the preset smoke temperature, or it is determined that the maximum temperature value of the environmental image is greater than the preset reactant thickness standard combustion temperature, or it is determined that the third ratio is greater than the third preset threshold, the temperature field data of the environmental image is inconsistent with the operating state of the reactor reflected by the combustion state, and the operating parameter determining unit 306 outputs a data pending signal to remind an operator to manually determine the temperature field data and the combustion state of the environmental image.
In one embodiment, the data collection module 102 may also collect the environmental image inside the reactor and the operating condition data of the reactor at the same time. The operating condition data may include, for example, reaction temperature, furnace pressure, reactant weight, and reactant type, among others. Wherein, the reaction temperature of the reaction furnace can be measured through a contact temperature measurement technology so as to monitor the running state of the reaction furnace. The contact type temperature measurement technology comprises a thermocouple temperature measurement technology and an infrared temperature measurement technology. In the thermocouple temperature measuring technology, thermocouples are arranged around the wall of a reaction furnace in a mode of punching holes on the furnace wall, and the reaction state of the reaction furnace is monitored through the temperature monitored by the thermocouples. The infrared temperature measurement technology utilizes an infrared sensor to detect the infrared band radiation intensity emitted by the surfaces of the reaction furnace and a measured object in the reaction furnace, and measures the temperature of the reaction furnace according to the relation between the infrared band radiation intensity and the temperature to monitor the reaction state of the reaction furnace.
The data processing module 104 can determine the operation parameter adjustment value of the reaction furnace by combining the temperature field data, the combustion state and the working condition data in the environment image, adjust the current operation parameter of the reaction furnace by using the operation parameter adjustment value, adjust the operation progress of the reaction furnace in real time according to the environment image of the reaction furnace, improve the accuracy of adjusting the reaction furnace in real time, simplify the flow of observing the combustion state when manually adjusting the reaction furnace, and improve the automatic control efficiency of the reaction furnace.
FIG. 5 is a block diagram of an automated reactor control system according to another embodiment of the present disclosure.
Referring to fig. 5, the data acquisition module 502, the data processing module 504 and the control module 506 in the automatic control system 500 of the reaction furnace respectively implement the functions of the data acquisition module 102, the data processing module 104 and the control module 106 in the system shown in fig. 1, and are not described herein again. In addition, the automatic control system 500 of the reaction furnace may further include a protection module 508, the protection module 508 collects environmental parameters outside the data acquisition module 502, and controls the data acquisition module 502 connected thereto to enter or exit the reaction furnace according to a result of calculating the environmental parameters, so as to prolong a working life of the data acquisition module 502 in a high temperature environment and improve safety of the data acquisition module 502.
FIG. 6 is a schematic view of the overall working environment of the automatic control system of the reaction furnace according to an embodiment of the present disclosure.
Referring to fig. 6, when the data acquisition module 102 is installed on a side wall of the reaction furnace, the automatic control system 600 of the reaction furnace includes a feed port 602, a combustion section 604, an ember section 606, ash 608, a flue gas pipe wall 610, a PLC (Programmable Logic Controller) control cabinet 612, a PC terminal 614, a cooling air input interface 616, a CCD (Charge Coupled Device) camera 618, an advance and retreat structure 620, an observation port 622, a cooling air output port 624, and a reactant 626. The CCD camera 618 is used to implement the function of the data acquisition module 102, the PC terminal 614 is used to implement the function of the data processing module 104, and the PLC control cabinet 612, the cooling air input interface 616, the forward/backward structure 620, and the cooling air output port 624 jointly implement the function of the protection module 108.
The CCD camera 618 is provided with an interface for transmitting image data, the interface is provided with a camera power switch connected to a power supply, the CCD camera 618 is connected with the PC end 614 through a gigabit Ethernet cable, the CCD camera 618 also transmits the image data with the PC end 614 through the gigabit Ethernet cable, the PC end 614 processes the received image data through an image software algorithm, determines an operation parameter adjusting value of the reaction furnace, and inputs the operation parameter adjusting value into a control module of the reaction furnace so as to adjust the operation parameter of the reaction furnace through the control module.
In one embodiment, an operator places the CCD camera 618 into the observation port 622 of the reaction furnace, directs the lens to the combustion section and the burnout section of the reaction furnace grate, turns on the power supply of the CCD camera 618, starts the automatic control system of the reaction furnace, turns on the temperature measurement software on the PC terminal 614, observes the acquired environmental image of the CCD camera 618, and can acquire a clearer environmental image by adjusting the aperture, the focal length and the exposure time of the CCD camera 618, so that the acquired image data meets the process requirements, the PC terminal 614 processes the acquired image data, and displays the processed result to the operator in real time.
The automatic reaction furnace control system 600 does not need complex spectrometer equipment, reduces the equipment cost, simultaneously performs non-contact temperature measurement on the reaction furnace, outputs temperature field data of the reaction furnace and the combustion state of the reaction furnace (including normal combustion, combustion abnormality in a combustion section, combustion abnormality in a burnout section, reactant thickness abnormality, smoke dust abnormality and the like) in real time, and controls the operation state of the reaction furnace according to the temperature field data of the reaction furnace and the combustion state of the reaction furnace.
FIG. 7 is a schematic view of the overall working environment of the automatic control system of the reaction furnace according to another embodiment of the present disclosure.
When the installation position of the data acquisition module 102 is above the furnace top in the reaction furnace, as shown in fig. 7, the automatic control system 700 of the reaction furnace includes a feed inlet 702, a combustion section 704, a burn-out section 706, ash 708, a flue gas duct wall 710, a PLC control cabinet 712, a PC end 714, a cooling air input interface 716, a CCD camera 718, an advancing and retreating structure 720, an observation port 722, a cooling air output port 724, and a reactant 726. Please refer to fig. 6 for the control process of the automatic control system 700 of the reactor, which is not described herein.
In one embodiment, taking the combustion grate as the combustion section 704 and the burn-out grate as the burn-out section 706 as an example, a chain structure composed of a chain wheel and a chain is arranged between the combustion grate and the burn-out grate, the chain is driven by the rotation of the chain wheel to roll by the combustion grate, reaction products on the combustion grate can be pushed to the burn-out grate at the rear part, and the burn-out grate discharges burned ash out of the reaction furnace. Therefore, after the reactant enters the reaction furnace, the reactant is firstly combusted on the combustion grate, and then the reaction product is continuously combusted on the burn-out grate, so that the reactant can be fully combusted, the combustion efficiency of the reactant is improved, and the discharge amount of pollutants of the reaction furnace is reduced.
Fig. 8 is a schematic view of a reactor operating process 800 controlled by the automatic reactor control system 100 shown in fig. 1.
As shown in fig. 8, an imaging system 802 is used to implement the functions of the data acquisition module in fig. 1, an image processing system 804 is used to implement the functions of the data processing module in fig. 1 or fig. 2, and an operation system 806 is used to implement the functions of the control module in fig. 1.
The imaging system 802 may include an industrial camera, which may be, for example, a flame detector and a high-temperature camera, and before the imaging system 802 collects an environmental image, an operator assembles the flame detector 802 and pre-adjusts the collection effect of the environmental image according to the characteristics of the high-temperature camera, such as the focusing characteristic, the exposure mode, and the shutter speed, so as to correct the brightness and the gray scale of the environmental image. The imaging system 802 sends the acquired environmental image to the image processing system 804.
In the image processing system 804, the collected environment image is sequentially subjected to noise reduction, filtering processing, normalization, graying and other processing, a preset temperature calibration relation between the image data and the temperature of the reaction furnace is obtained, the image data is converted into temperature field data in real time, meanwhile, a preset neural network model is used for obtaining a combustion state corresponding to the image data, a process algorithm for obtaining the temperature field data of the reaction furnace and a combustion state representing the operation state of the reaction furnace according to the environment image is established, and an operation parameter adjusting value of the reaction furnace is determined according to the temperature field data and the combustion state.
In addition, after the gray scale processing of the environment image is realized by taking the same value for the gray scale values corresponding to the RGB values (representing the red, green and blue color modes) of the environment image in the process algorithm, the extraction difficulty in extracting the image characteristic data of the environment image can be reduced, and the external influence of the smoke dust in the reaction furnace on the environment image acquisition of the imaging system 802 can be reduced.
The operation system 806 receives the operation parameter adjustment value from the imaging system 802 to adjust the operation parameters of each operation mechanism of the reaction furnace in real time, so as to achieve the purpose of automatically controlling the reaction furnace.
Fig. 9 provides a schematic diagram of a reactor condition monitoring device.
As shown in fig. 9, the reactor status monitoring apparatus 900 includes a data acquisition module 902, a data processing module 904, and an automatic advance/retreat protection module 906. The automatic forward and backward movement protection module 906 is connected with the data acquisition module 902, and protects the data acquisition module 902 from working normally in the reaction furnace according to the acquired external environmental parameters of the data acquisition module 902. The data acquisition module 902 sends the acquired environmental image in the reaction furnace to the data processing module 904 connected with the data acquisition module, so that the data processing module 904 determines the temperature field data and the combustion state of the reaction furnace according to the environmental image.
The functions of the modules in the apparatus shown in fig. 9 are the same as those of the modules shown in fig. 1 and 5, and the detailed description of the disclosure is omitted here.
The reactor state monitoring device 900 of the embodiment can monitor the running state of the reactor in real time, and has the advantages of simple structure, flexible installation position and strong maintainability.
According to the automatic control system of the reaction furnace provided by the disclosure, the current combustion condition in the reaction furnace can be directly reflected, the running state of the reaction furnace is adjusted according to the combustion condition, the reaction temperature stability and the reaction efficiency of reactants in the reaction furnace are improved, the discharge amount of harmful substances such as dioxin is reduced, meanwhile, the heat energy generated in the reaction process of the reaction furnace is improved, the utilization rate of the heat energy of the reaction furnace is improved, and the heat energy generated by the reaction furnace can be used for generating electricity.
The automatic control system of the reaction furnace provided by the disclosure is applied to the field of waste incineration, and when waste with complex components, high moisture content and low heat value in the furnace is subjected to automatic incineration control, the control efficiency of waste incineration is improved, pollutants generated by waste incineration are reduced, and the problems that waste burns partially, the incinerated pollutants exceed the standard and the like are solved.
Use this reaction furnace automatic control system who openly provides in the industrial boiler field, when carrying out automatic incineration control to the solid fuel that humidity is big, the ignition point differs, can improve the degree of automation of boiler work, reduce the human cost, improve the combustion efficiency of fuel, reduce the discarded object that the burning produced, improve industrial boiler's work efficiency.
The above-described figures are merely schematic illustrations of the processes involved in the method according to an exemplary embodiment of the invention, and are not intended to be limiting. It will be readily understood that the processes shown in the above figures are not intended to indicate or limit the chronological order of the processes. In addition, it is also readily understood that these processes may be performed synchronously or asynchronously, e.g., in multiple modules.
Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure disclosed herein. This application is intended to cover any variations, uses, or adaptations of the disclosure following, in general, the principles of the disclosure and including such departures from the present disclosure as come within known or customary practice within the art to which the disclosure pertains. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the disclosure being indicated by the following claims.
Claims (10)
1. An automatic control system for a reaction furnace, comprising:
the data acquisition module is used for acquiring an environment image in the reaction furnace;
the data processing module is connected with the data acquisition module and used for acquiring temperature field data and a combustion state according to the environment image and determining an operation parameter adjusting value of the reaction furnace according to the temperature field data and the combustion state;
and the control module is connected with the data processing module and the reaction furnace and is used for adjusting the operation parameters of the reaction furnace according to the received operation parameter adjusting value.
2. The automatic control system of claim 1, wherein the data acquisition module is further configured to acquire operating condition data of the reactor, and the data processing module is further configured to determine an operating parameter adjustment value of the reactor according to the operating condition data, the temperature field data, and the combustion state.
3. The automatic control system of a reaction furnace of claim 1, wherein the data processing module comprises:
the combustion state identification unit is used for identifying the environment image through a preset neural network model so as to obtain the combustion state, and the combustion state comprises at least one of combustion abnormity of a combustion section, combustion abnormity of an ember section, smoke abnormity, reactant thickness abnormity and furnace shutdown;
the temperature field identification unit is used for identifying the environment image according to a preset temperature calibration relation to acquire temperature field data, wherein the temperature field data comprises a plurality of temperature values corresponding to the environment image, and the preset temperature calibration relation is a corresponding relation between image pixels and the temperature values;
and the operating parameter determining unit is used for determining an operating parameter adjusting value of the reaction furnace according to the temperature field data and the combustion state.
4. The automatic control system of the reaction furnace according to claim 3, wherein when the combustion state is abnormal combustion in a combustion section and the first ratio of the temperature field data is less than or equal to a first preset threshold, the operation parameter determination unit determines an increase value of an intake air amount and an increase value of a grate speed;
the first ratio is the ratio of the number of temperature values exceeding the combustion temperature of the preset combustion section to the total number of the temperature values, the air intake increase value is used for increasing the air intake of the reaction furnace, and the grate speed increase value is used for increasing the grate speed of the reaction furnace.
5. The automatic control system of a reaction furnace according to claim 3, wherein the operation parameter determination unit determines an intake air amount reduction value and a grate speed reduction value when the combustion state is an ember zone combustion abnormality and the second ratio of the temperature field data is greater than or equal to a second preset threshold;
the second ratio is the ratio of the number of temperature values larger than the combustion temperature of the preset ember section to the total number of the temperature values, the intake air reducing value is used for reducing the intake air of the reaction furnace, and the grate speed reducing value is used for reducing the grate speed of the reaction furnace.
6. The automatic control system of claim 3, wherein the operation parameter determination unit determines an increase in the intake air amount when the combustion state is a smoke abnormality and a maximum temperature value in the temperature field data is less than or equal to a preset smoke temperature.
7. The automatic control system of claim 3, wherein the operation parameter determination unit determines the intake air increase value and the grate speed increase value when the combustion state is abnormal in reactant thickness and the maximum temperature value in the temperature field data is less than or equal to a preset reactant thickness standard combustion temperature.
8. The automatic control system of the reaction furnace according to claim 3, wherein when the combustion state is a furnace shutdown and a third ratio in the temperature field data is less than or equal to a third preset threshold, the operation parameter determination unit determines that the air intake of the reaction furnace, the feeding amount of the reaction furnace and the grate speed of the reaction furnace are zero;
and the third ratio is the ratio of the number of temperature values smaller than the preset blowing-out temperature to the total number of the temperature values.
9. The automatic control system of a reaction furnace according to claim 1, further comprising:
and the protection module is connected with the data acquisition module and used for acquiring the external environmental parameters of the data acquisition module and controlling the data acquisition module to enter or exit the reaction furnace according to the environmental parameters.
10. A reactor condition monitoring device, comprising:
the data acquisition module is arranged on the side wall of the hearth of the reaction furnace and used for acquiring an environment image inside the reaction furnace;
the data processing module is connected with the data acquisition module and used for determining the temperature field data and the combustion state of the reaction furnace according to the environment image;
and the automatic advancing and retreating protection module is arranged outside the data acquisition module and used for acquiring the external environmental parameters of the data acquisition module and controlling the data acquisition module to enter or exit the reaction furnace according to the environmental parameters.
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